CAEDSMouldPartsManufacturing

Introduction
TampereUniversityofTechnologyTuulaHk

Usuallyamouldisfabricatedtoastandardmouldset.Theminimumstandardmould Standardmouldset
set assembly consists of two cavity plates, in some constructions a back plate, two
clampplates,risersandanejectorset.












Astandardmouldset



Inadditiontoastandardmouldset,thereisaneedforseveralfunctionalmouldparts Functionalparts
including:
cavityplateguides
ejectorplateguides
ejectors
ejectorreturnpins
mouldcavitysupportpillars
runnersystemparts:spruebushing,centringflange,specialgateinserts(for
exampletunnelgate)andhotrunnersystems
differentequipmentsandpartsformovingcores:slidingcoremechanism
parts,springs,hydraulicandelectriccorepullingcylinders
ejectorbarsandpartsforfasteningtheejectorplatestothecastingmachine
fittings,nozzlesandbafflesforthemouldcoolingandtemperinglines
insulatingplatesfortheinjectionmoldingmould
differentmechanismsforexampleformoldingthreadsandfortwostageejec
tion,datestampsetc.

Standard mould sets and other mould parts are purchased from local sales agents.
Some of the largest standard mouldset and standard mould part manufacturers are
listedinthefollowingtable.

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 CAEDSMouldPartsManufacturing

Manufacturer Products Manufacturers

Cumsa; Standardmouldparts
http://www.cumsa.com

DME; Standardmouldsetsandmouldparts
http://www.dmeeu.com Hotrunnersystems

FCPKBytow; Standardmouldsetsandmouldparts

http://www.fcpk.pl


Hasco; Standardmouldsetsandmouldparts

http://www.hasco.com Hotrunnersystems

Meusburger; Standardmouldsetsandmouldparts
http://www.meusburger.com

Rabourdin; Standardmouldsetsandmouldparts
http://www.rabourdin.fr Hotrunnersystems

Strack;http://www.strack.de Standardmouldsetsandmouldparts
Hotrunnersystems

Machining
To be able to put a mould together from these parts, there is a need for different
methods
machiningoperations.Thebasicoperationsare:

mouldcavityandcoremachining
runnerandventingsystemmachining
temperingchannelsfabrication
machiningofthebasicgeometriesforassemblingthestandardmouldpartsto
theset

The most common machining methods used in the mold manufacturing operations
areconventionalandhighspeedmilling,conventionalanddeepholedrilling,grind
ing and electric discharge machining (EDM). Mould cavity plates, cores and inserts
areusuallyheattreatedbetweenroughandfinishmachining.Theheattreatedsteelis
bestmachinedwithanEDMorahighspeedmillingmethod.Theapplicationsofthese
methodsarelistedinthefollowingtable.

There are different finishing methods for the mould cavity surfaces. They are pol Cavitysurface
ished,texturisedorleftastheyareaftertheEDMoperations.Polishedmouldcavity finishing
surface produces shiny injection molded parts. Polished cavity is also essential in
producing transparent parts. EDM methods leave small sinks to the mould cavity
surface.Thesinksizedependsontheelectricchargeintensity.Sometimesthisisthe
desired situation, because these small sinks produce a decorative surface to plastic
parts.

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 CAEDSMouldPartsManufacturing

In pressure die casting the small EDM sinks are nucleation points for heat cracking
and there is a need to completely remove the upper deformed mould surface. The
pressurediecastingmouldsarenotpolished.Acertainsurfaceroughnessislefttothe
cavitytohelpthereleaseagenttowetthesurface.

Machining Application Machining
method methods

Conventional Geometriesforassemblingthemouldpartsandfor
milling fasteningthemouldtothemachinetables
Mouldcavityroughmilling
Coreroughmilling
Ejectorshaping
Highspeed Mouldcavityfinishmachining
milling Corefinishmachining

Drilling Ejectorholemachining
Fasteningelements,threadholes

Deephole Mouldtemperingandcoolinglinedrilling

drilling Sensorholes

Grinding Partingsurfacefinishing
Slidingsurfacefinishing
Cavitysurfacefinishing
EDM Mouldcavitymachiningeitherastheonly
machiningmethodortogetherwithhighspeed
milling
WireEDM Ejectorholemachining
Corepinholemachining
Ejectorcuttingandshaping
Corepincuttingandshaping
Lasersintering, Cavitysurfacetexturisingandfinishing
chemicaletching,
etc.

Polishing Cavitysurfacefinishing

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